Structural building panel unit



G. W. MEEK STRUCTURAL BUILDING PANEL UNIT Dec. 25, 1962 4 sheets-sheet 1 Original Filed May 10, 1955 Dec. 25, 1962 G. w. MEEK STRUCTURAL BUILDING PANEL UNIT 4 Sheets-Sheet 2 Original Filed May 10, 1955 J M r m an a I v R h kw M wv NQ E N a Dec. 25, 1962 c. w. MEEK STRUCTURAL BUILDING PANEL UNIT 4 Sheets-Sheet 3 Original Filed May 10 Dec. 25, 1962 G. w. MEEK 3,070,186

STRUCTURAL BUILDING PANEL UNIT a 1 z a 4 5 e 7 8 ms. S/IND PER sa-fl' lflNEl.

V w CYCLES PER sEm/vn klwtmg'smv mom SOUND FREQUENCIES 3,070,186 STRUCTURAL BUILDING PANEL UNIT George W. Meek, Pelham, N.Y., assignor to American W.M.B., Inc., New York, N.Y., a corporation of New York The present invention relates to structural building paneled wall constructions and panel means thereof, preferably in the form of units readily connected together and to other means quickly to form such wall constructions. This is a division of application Serial No. 507,251, gledgvlay 10, 1955, now Patent No. 2,893,067, dated July A general object of the present invention is to provide such wall constructions of a sturdy nature which are quickly and easily erected with the use of unique panel units readily and securely fastened together in a novel manner and by novel means which assure complete concealment of the latter, and relatively light-weight panel units which may be employed to advantage in such erection and which have unusual sound transfer suppressing characteristics.

A more specific object of the present invention is to provide such panel units in a form permitting secure fastening of juxtaposed edges of adjacent ones thereof by simple concealed fasteners easily manipulated toconnecting positions in an unusually simple manner after concealment in junctions between adjacent panel units.

Another object of the present invention is to provide such panel units with interfitting abuttable side edge flanges which may be locked together at a junction remotely from the opposite side edge of one of the units by rotation of clamping clips concealed in the junction.

A further object of the invention is to enhance the sound transmission losses through such panel units and wall constructions made therewith by unique loading of cells in the core bodies of such units with unusual sound suppressing material. A still further object of the invention is to load cells of core bodies of such panel units which'intervene sheathing face sheets of the latter, with free-flowing granular material whereby transfer of sounds of frequencies within a range constituting that which causes the most annoyance to business building occupants is suppressed to an unusual and efficient degree.

Still another object of the invention is to provide structural embodiments which are readily and economically constructed on a mass production basis and which permit efficient use thereof.

Other objects of the invention will in part be obvious and will in part appear hereinafter.

The invention accordingly comprises the features of construction, combinations of elements, and arrangement of parts, which will be exemplified in the constructions hereinafter set forth, and the scope of the invention will be indicated in the claims. For a fuller understanding of the nature and objects of the invention reference should be had to the following detailed description taken in connection with the accompanying drawings, in which:

United States PatentO "ice FIG. 1 is a perspective view, with parts broken away and in section, of a typical wall construction embodying panel units connected together and anchored in accordance with the present invention;

FIG. 2 is a sectional view taken substantially on line 22 of FIG. 1;

FIG. 3 is a sectional view, with parts. broken taken substantially on line 33 of FIG. 1;

FIG. 4 is a vertical sectional view, with parts broken away, of the wall construction shown in FIGS. 1, 2 and 3, taken substantially on line 4-4 of FIG. 1;

FIG. 5 is a sectional detail view to reduced scale, with parts broken away, of a modified form of connecting and fastening means used at junctions of the panel units of the wall construction illustrated by way of example in FIGS. 1 to 4 incl.; 1 I

FIG. 6 is a sectional detail view similar to FIG. 5 of a further modification of the fastening and connecting means; f

FtG. 7 is an enlarged perspective view of a clamping clip used as a fastening and connecting means at the panel unit junctions of the wall construction illustrated in FIGS. 1 to 4 incl.; i i

FIG. 8 is a transverse sectional view to reduced scale, with parts broken away, of a further modified-form of connecting and fastening means employed at a panel unit junction of a wall construction similar in some respects to that illustrated in FIGS. 1 to 4 incl.;

FIG. 9 is an enlarged side elevational view of the modified form of fastener or clip used in the FIG. 8 junction structure;

FIG. 10 is an enlarged exploded perspective view,'with parts broken away, of the ceiling channel assembly shown in FIGS. 1, 3 and 4;

FIG. 11 is a vertical sectional view, with parts broken away, taken substantially on line 5'5 of FIG. 1;

FIG. 12 is an enlarged vertical sectional view, with parts broken away, of a modified form of ceiling channel illustrating its use in anchoring to ceiling structure the upper end of panel units of the present invention;

FIG. 13 is an enlarged horizontal sectional view, with parts broken away, of a door buck or frame showing anchorage thereto of the side of a panel unit of the present invention; A

FIG. 14 is an enlarged sectional view of a simplified form of ceiling channel;

FIG. 15 is an enlarged horizontal sectional view, with parts broken away, of a typical intersection;

FIG. 16 is an enlarged horizontal sectional view, with parts broken away, of a typical 90 corner construction employing panel units of the present invention;

FIG. 17 is a perspective view graphically illustrating steps in the construction of a panel unit of the present invention and particularly the loading with granular freeflowing material of the cells of the core means before the final application of the last sheathing sheet to the latter;

FIG. 18 is a plotted curve indicating sound transmission loss advantages of loading of the type illustrated in FIG. 17; and in FIG. 19 is shown three plotted curves illustrating sound transmission loss by various degrees of loading of the type illustrated in FIG. 17 and at various sound frequencies.

Referring to the drawings, in which like numerals identify similar parts throughout, it will'be seen from away,

FIGS. 1 to 4 incl., 7, and 11, that a structural building paneled wall construction may, in accordance with the present invention, comprise the following parts. Such a wall construction preferably is employed as a partition but it is to be understood that if desired such construction may, in certain instances, be employed as outside building wall construction. Let it be assumed that it is desired to employ the wall construction 20 as a partition to extend laterally from a masonry wall unit 21 between suitable floor structure 22 and suitable ceiling structure 122. There is suitably mounted upon the floor structure 22 a floor channel 23, laterally-spaced side channels 24 and 25, and a ceiling channel 26 to receive therebetween and anchor a plurality of substantially aligned panel units, as hereinafter explained.

. The floor channel 23 may, as will be seen from FIGS. 1 and 11, comprise a base web 27 and side flanges 23, 28.. The edge portions of the side flanges 28, 28 may each be shaped in the manner best seen in FIG. 11 to provide oblique sections 29, 29 merging with the upright main portions of these flanges, and additional interior, laterally-spacedand opposed, L-shaped flanges 30, 30. The ,sL-shaped flanges 30, 30 cooperate to receive and support the. bottom end portion 31 of a suitable panel unit 32, a plurality of the latter being abutted edge-toedge for, substantial alignment to form the partition.

The side Wall channel 24 may be of simple construction including a. transverse web 33 flanked by a pair of side flanges 34, 34between which a side edge of panel unit 32 may be seated, as seen in FIG. 1. The other sidewall channel ,25- may be of two-part construction, similar if desired to the ceiling channel assembly 26 (as indicated in FIG. 2), so that a plurality of panel units, such as 32, may be assembled in the floor channel 23, edge-to-edge, substantially to fill up the Wall gap, With the parts of the side wall channel 25 then being as sembled or wedged into position from opposite sides, as will be more fully understood in connection with the description of the ceiling channel 26.

As illustrated in FIGS. 1, 3, 4 and 10, the ceiling channel assembly 26v preferably is formed of two companion parts or sections 35 and 36', each of general L-shaped configuration in cross-section. Each of the L-shaped channel sections 35 and 36 has a sloping side flange panel 37 with its free edge provided with a reverse bend 38 to trim the junction with the panel units and between which the top end portions 131-131 of the latter are snugly clamped, as is best seen in FIGS. 3 and 6. The L-sh aped section-35 has a lateral web panel 39 to the underside of which is affixed by suitable means, such as spot welding, a plurality of longitudinally-spaced spring clips or tongues 40-40. The channel section 36 also has a lateral web panel 41, the free edge of which is provided with a reverse bend 42 to form an enlarged bead which may be wedged between the web panel 39 and the plurality of clips 40-40, permitting the latter to snap in behind the bead and secure the two channel sections 35 and 36 together, thus forming the channel assembly 26. It will be understood that such channel assembly structure permits the two sections 35 and 36 thereof to be inserted from opposite sides of the panel units in a relatively small space intervening ceiling structure 122 and the upper end portions 131-131 of the panel units. The channel section 35 preferably is suitably fastened in position against ceiling structure 122 by suitablemeans, such as nails or screws, at the time floor channel 23 and side wall channel 24 are mounted. After the panel units (such as 32) are assembled in the floor channel 23 with their top end portions 131-131 swung up into fixed channel section 35, the other channel section 36 may be driven inward from the opposite side with its lateralweb panel 41 received below the lateral web panel 39 of the fixed channel section 35, so that the bead 42 will snap in between the latter and the clips 40-40 to the locked position illustrated in FIG, 3. As

previously suggested and as is illustrated in FIG. 2, the side channel 25 may be an assembly similar to that of ceiling channel 26, and the parts thereof may be mounted in similar fashion.

Consequently, the plurality of panel units 32 may be assembled edge-to-edge in substantial alignment to provide the partition wall construction 20 by first inserting the bottom end portion 31 of one panel unit in the previously mounted floor channel 23 While the panel unit is in a tilted position and swinging the top end portion 131 of the panel unit upward to substantially vertical position with nesting of the top end portion in the previously mounted channel section 31 and with one face abutted against reverse bend 38 of this fixed channel section. Then the panel unit 32 is slid laterally along floor channel 23 to insert the far side edge of the former into the side wall channel 24. The succeeding panel units, such as 32 and 132 as illustrated in FIGS. 1 and 2, may thereafter be progressively added in a similar fashion with edge portions of adjacent panel units brought to abutment in junctions so as finally to fill the wall gap. Subsequently, the second ceiling channel section 36 is mounted in the indicated manner, i.e. its lateral web panel 41 is inserted between the top end portions 131-131 of the upright panel units and lateral web panel 39 of the fixed channel section 35, and then it is driven inwardly to snap bead 42 in behind the clips 40-40, locking the parts together. Finally the second section of side wall channel 25 is mounted in similar fashion to complete the partition wall construction 20. During the successive mountings of the panel units 32-32 and 132-132 to fill up the Wall gap, suitable fastening elements are added and manipulated effectively to lock together the adjacent subsequentially aligned panel units at their junctions, as will be understood from the description here following.

If desired, the partition wall construction 20 may embody framed openings, such as doors and/ or windows. For example, a window opening 43 may be provided by inserting a pair of vertically-spaced shorter panel units 132, 132, which are similar in all other respects to the longer panel units 32-32, and the window opening may be suitably framed with sections 44-44 of trim channel, as will be understood from FIGS. 1 and 3.

Each wall panel unit 32 or 132 includes a pair of transversely-spaced sheathing face sheets 45, 45 intervened by suitable core means 46. Such wall panel units 32 and 132 may be standardized as rectangular structures of convenient dimensions, such as about eight feet long and one or more feet wide. Although in the illustrated embodiment of the invention, as may appear from FIGS. 1, 2 and 4, each of the panel units 32 and 132 may be several feet in width, it is preferable that they be in the form of planks, such as about one foot in width, so as to facilitate shipping and handling. The sheathing sheets 45, 45 may be formed of a variety of materials, such as sheet metal, e. g. sheet steel or aluminum, fiber or wood sheets, asbestos board, etc., and may, if desired, be of laminated construction. For example, the sheathing sheets 45, 45 may be formed of suitable plywood with the plies thereof laminated or bonded together by suitable adhesive and natural wood grain in outside plies may constitute a desirable decorative feature or provide a desired pleasing ornamental effect. The faces of all such panel units or planks may be ornamentally enhanced by reeding or other configurations. Also, obscuring coatings may be employed, such as paint or wallpaper. Structurally, such panel units 32 and 132 may be constructed in the manner proposed in Munters Patent 2,417,435 of March 18, 1947, wherein the sheathing sheets, which may be of steel sheeting of about No. 20 to No. 26 gauge (0.031" to 0.015"), are intervened by suitable porous core means in the form of corrugated material providing or defining transverse core chambers or cells extending transversely between the inner faces of the sheets. Such act-raise sheathing sheets 45, 45 may be provided in pre-cut'and shaped form and assembled with intervening bodies of core means 46 with the application of bonding adhesive between the inner faces of the sheets and the outer faces (or edges of the through cells) of the core means. For example, such a panel unit may be constructed in a width of about one foot (1), with the use of sheathing sheets of steel of a thickness of 0.025 and with the core means 46 formed of paper impregnated with the asphalt or phenolic resin, the overall thickness of the plank being about three inches (3"). Such panel unit planks are light in weight and can readily be handled and shipped economically. Also, such planks can be trimmed on the job to adapt them to ceiling heights different from the standard lengths of the planks by light-weight mechanized hand saws.

The core means 46 which intervenes the sheathing face sheets 45, 45 is readily pierced by a stiff rod such as the elongated stern of a steel fastener-manipulating tool, as will be more fully explained hereinafter, and is exposed for access in the side edges of the panel units by transverse spacing of shaped edge portions 4'7, 47 and 48, 48. The core means 46 may be of uniform construction throughout a plank, such as in the form of the cellular corrugated configuration described above, or, as is indicated in FIGS. 2 and 4, laterally-spaced vertical zones between the facing sheets 45, 45 may be filled with such core means, such as at 49, 49. The intervening vertical spaces 50- 50 may be filled With any other suitable ma terial, such as mineral wool or particulate insulating material, or left free for running plumbing and electrical wiring. When the spaces 505'0 are loaded with filler material the latter also preferably is of a type which will permit ready piercing by and passage of stiff rods.

The shaped flanges 47, 47 and 48, 48 are made complementary to each other for interfitting juxtaposed edges of adjacent panel units or planks at junctions. For example, the edge portions 47, 47 may be turned inwardly transversely of the panel unit and then laterally outward to provide L-shaped flanges, and the edge portions 48, 48 may be turned inwardly transversely of the panel unit and then laterally in behind the facing sheets 45, 45 to form reverse bends. The reverse bends at 43, 48 mate with or nest in the L-shaped flanges at 47, 47, as will be seen from FIG. 2. Thus the two transversely-spaced, L-shaped side flanges 47, 47 along one side edge of a panel or plank unit 32 or 132 together form tongue means which seats into a longitudinally-extending groove provided or defined in the other edge of the panel unit or plank by the transversely-spaced pair of reverse bent side flanges 48, 48. Also, as illustrated in FIG. 2, in the nesting of a reverse bent flange 48 with an L-shaped flange 47 the free edge 51 of the reverse bend extends laterally in behind facing sheet 45 farther than the free edge of the L-shaped flange 47, and this free edge 51 forms one of a pair of abutment means. The transversely-extending web of the L-shaped flange 47 has a back face 52 which serves as the other of the pair of abutment means, with those two abutment means 51 and 52 facing in opposite directions.

The nested or mated pairs of L-shaped and reverse bent flanges 47, 48 are, as best seen from FIG. 2, adapted to be connected or clamped together by suitable fastening means so that the adjoining planks or panel units are fastened to ether at their junction. As illustrated in the embodiment of FIGS. 1 to 4 incl. and 7, such clamping means may be in the form of a plurality of fasteners or clamping clips 53-53. Each of said clamping clips 53 preferably is an elongated structure having opposite end portions with each end portion forked or bifurcated to provide two pairs of laterally-spaced fingers, 54, 54 at one end 55, 55 at the other end, with those two pairs of laterally spaced fingers being like but shaped in reverse order so as to have leading and trailing edges arranged in the same clockwise order. As will be best seen from FIG. 7, such clamping clip 53 has an intermediate portion 56 provided with a tool-receptive hole 57 which is other than round in configuration, such as rectangular, to receive the complementary shaped end of a tool stem for rotating the clamping clip. Assuming that the clip 53 as illustrated and viewed in FIG. 7 is to be rotated in a clockwise direction, the leading corners 58, 58 of the laterally-spaced fingers 54, 54 are bent outwardly so as to facilitate reception therebetween of paired abutment means when the clip is rotated. Likewise, the leading corners '59, 59 of the laterally-spaced fingers 55, 55 on the opposite end portion of the clamping clip 53 are bent outwardly for a like purpose. Also, the paired fingers 54, 54 and 55, 55 are so shaped that the spaces therebetween are generally V-shaped so as to apply wedging action to the received pairs of abutment means. Such a clamping clip 53 may be readily formed from two shaped strips of sheet steel suitably spot welded together in the mid-section 36, as will be understood from FIG. 7.

A tool 60 for rotating each of the clamping clips 53 may be in the form illustrated in FIG. 4 comprising an elongated rod-like stem 61 having a free end 62 shaped complementary to the hole 57 in the clip, thus preferably being flatted or generally rectangular in cross-section.

The opposite end of the tool stem 61 is conveniently pro-- vided with an enlarged head, such as a cross bar 63, to permit ready manual rotation thereof. Such tool 60 preferably is formed of steel and thus has appreciable stiffness, permitting it to be pierced through the core means 56 from one exposed edge thereof between flanges 47, 47 to the other exposed edge thereof between flanges 48, 48. Thus, a plurality of the tool 60 may be employed to pierce through the core means 46, at suitable vertically-spaced locations, laterally-extending passages for reaching through to the clips 53-53 for rotational operation thereof. It will be understood, however, that such lateral passages, such as that indicated at 64 in FIG. 4 as being formed by piercing with the tool stem 61 and to be formed at 164164, may be pre-formed by any other suitable means in the manufacture of the panel units or planks.

In constructing the partition wall construction illustrated at 20 in FIGS. 1 to 4 incl., the first panel unit 32, which will be found on the left side of FIGS. 1 and 2, will be positioned in the floor channel 23 and the side wall channel 24 in the manner indicated above. Then planks 132, 132 are juxtaposed to the first plank with their L-shaped flanges 47, 47 received in between the. reverse bent flanges 48, 48 of such first plank. Prior to.

juxtaposing the fore-shortened planks 132, 132 to the first plank 32, a plurality of the tools 6060 are pierced laterally through the core means 46 of the foreshortened planks at suitably selected locations, such as is illustrated at 64 and indicated at 164 and 164 in FIG. 4. The leading shaped end 62 of the tool is pushed out to extend beyond the far side edge of the plank 132 there to receive one of the clamping clips 53 temporarily to carry the same until the juxtaposed plank can befastened or connected to the first plank by the clips. Then plank 132, carrying the plurality of tools 6060 with the plurality of clips 53-53 supported on the protruding ends 62-62 thereof, is moved to position adjacent the first plank 32, with its side edgecarrying the pair of transversely-spaced L-shaped flanges 47, 47 abutted against the opposed side edge of the first plank which carries the transverselyspaced reverse bent flanges 48, 48, to mate the flanges together. Then each tool 60 is rotated in a counterclockwise direction so that the laterally-spaced fingers 54, 54 swing down to receive therebetween the paired flanges 47 and 48 at one face of the panel units, and the other laterally-spaced fingers 55, 55 swing up to receive therebetween the other paired flanges 47 and 48 at the other face of the panel units, as the clip 53, carried by this particular tool, is rotated to a horizontal transverse position. Thus clip 53 is rotated from the dotted line free position indicated in FIG. 3 to the full line clamping or locked position shown therein. In rotation of each of the clips 53 by its tool 60, the spread tips 58, 58 of the laterally-spaced fingers 54, 54 engage to the outer sides of the pair of oppositely facing abutment means provided by the free edge 51 of the reverse bent flange 48 and the back face 54 of the L-shaped flange 47. Upon further rotation of the clip 53, those paired abutments 51 and 54 are wedged deeper into the V-shaped space between the fingers 54, 54 so as securely to clamp the paired flanges 47 and 48 together. The laterally-spaced fingers 55, 55 on the opposite end portion of the clip 53 perform a like clamping action upon the paired flanges 47 and 48 at the opposite face of the panel units simultaneously with the clamping of the paired flanges at the other face so as thus securely to fasten the juxtaposed edges of the adjacent planks together in their junction. This is accomplished within a concealed joint with the clips 5353 hidden therein behind the faces of the panel units or planks. Each of the plurality of clamping clips 53-53 is successively rotated to a transverse position in this manner by its own rotating tool 60, and after the forked or bifurcated end portions of the clips have respectively engaged and clamped therebetween the paired flanges 47, 48 and 47, 48 at the opposite faces of the panel units the tools are withdrawn to be used in the setting of the clamping clips for the next successive plank.

As indicated in FIG. 5, the paired abutment means may be provided by modified flange structure such as the back side of L-shaped flange 47 and the outermost edge 151 of a slot 65 in reverse bent flange 148. Also, as indicated in FIG. 6, the paired abutment means which preferably face in opposite directions to be engaged between the laterally-spaced fingers, such as 54, 54 of clip 53, may be provided as free edges 51, 51 of like reverse bent flanges 43, 48 and with those paired reverse bent flanges abutted together in face engagement rather than being nested as with respect to the mated flanges 47 and 48.

A modified form of the concealed or hidden fastening means which connect juxtaposed edges of adjacent panel units or planks together within the scope of the invention is illustrated in F168. 8 and 9. A there indicated, one of the panel units 232 may be provided with transverselyspaced, slotted reverse "bent flanges 148, 148 along one edge, and the opposite edge thereof, which will be the same as the juxtaposed edge of the next adjacent panel unit 232, is provided with a pair of transversely-spaced, slotted L-shaped flange 147, 147. In such a structure the outermost edge 151 of the slot in either of the reverse bent flanges 1'48 constitutes one abutment of a nested pair and the outermost edge 66 of the slot in the mated L-shaped flange 147 constitutes the opposed abutment of this pair. In such case, the fastening device 153, as is best seen in FIG. 9, may consist of an elongated bar medially provided with slot 57 to receive the shaped end 62 of the tool stem 61 and with its opposite ends 154 and 155 tapered to wedge into the aligned but oflset pair of slots in the mated flanges 147 and 148. Thus, as the fastener 153 is rotated, its tapered ends 154 and 155 wedge into the pairs of aligned slots at opposite faces of the juxtaposed panel units, gradually spreading apart the paired opposed abutments 66, 151 and 66, 151 to draw the flanges 147, 147 snugly about and against the flanges 148, 148.

As shown in FIG. 12, the ceiling channel assembly provided at 26 or the side wall channel assembly provided at 25 in FIG. 1 may be modified. Such modified channel assembly 126 (or 125) may comprise two similar channel half-sections 67 and 167, each of which has a downwardly-extending flange 68 provided on the free edge of its lateral web 139 and adapted to be abutted against that of the other. The abutted flanges 68, 65 are provided with a plurality of longitudinally-spaced, aligned holes 6969 through which elongated tie bolts 70--70 may be received. The side wall 71 of channel half-section 167 is also provided with a plurality of longitudinallyspaced holes 72-72, each preferably of countersink shape and transversely aligned with one of the holes 69 in the flange 63 of this channel half-section. Consequently, with channel half-section 67 mounted in any suitable manner to ceiling structure 122 and with the top end portion 131 of a panel unit 32 abutted against its reverse bent flange 38, the other channel half-section 167 can be positioned on the opposite side of the panel unit with its reverse bent flange 38 bearing against the opposite face of the panel unit for anchorage of the latter when the two channel half-sections are tied together. The flange 68 of channel half-section 67 may carry a captive nut 73 aligned with each of its holes 69 so that when a tie bolt 70 is pushed through the aligned holes 72 and 69 of the companion channel half-section 167, the externally-threaded leading end of the bolt will engage into the captive nut to draw the two channel half-sections tightly together.

As indicated in FIG. 13, panel units or planks 32 of the present invention may have their longitudinal edges readily and easily fitted with door framing or a buck column 74. The buck column 74 may be of hollow construction, having a slot in the back side 75 thereof into which the reverse bent flanges 48, 48 of panel unit 32 may be projected snugly to fit therein, as shown. If desired, trim molding 76, 76 of any suitable construction and desired shape may be fitted and anchored in any suitable manner in the angles between the sheathng face sheets 45, 45 of the panel unit 32 and the slotted side 75 of the buck.

Anchoring channel for such panel units may be of simplified construction, as is illustrated at 124 in FIG. 14, wherever ready access is permitted. For example, channel 124 may be substituted for side wall channel 24 of the partition wall construction 20 illustrated in FIG. 1 and may comprise web 33 and side flanges 134, 134 with the latter shaped to provide sloping panels 77, 77 having their free edges reversely bent, as indicated at 78, 78.

Panel units or planks of the present invention may be employed to construct typical 90 intersections, such as that illustrated in FIG. 15. As there proposed, three panel units or planks 3232, each having its sheathing face sheets 45 provided along one side edge with the reverse bent flanges 48, 48, may be brought together in a T- shaped joint for such intersection, with the reverse bent flanges 48, 48 of the intermediate panel unit or plank substantially abutted at right angles respectively to one such reverse bent flange 48 of the other two longitudinallyspaced and substantially aligned panel units or planks. An oblique bridging strip 79 covered with a right-angled flange 80 is anchored in any suitable manner to fill out the corner between one of the aligned panel units 32 and the intermediate panel unit 32, and to provide a flat web 81 against which reverse bent flanges 48, 48 of the third panel unit 32 are abutted. As shown in FIG. 16, the structure of FIG. 15 may also provide a right-angled corner, the bridging strip and covering flange 80 having their nested edges seating on L-shaped side flange 47, 47 of the juxtaposed panel units or planks 32, 32 which are arranged normal to each other.

Since embodiments of the present invention are particularly advantageous and specially designed for use in the erection of structural building paneled wall constructions, the transfer of sound therethrough is an important problem. One feature of the present invention solves this problem by providing simple means for suppressing sound transfer to an unusual degree. This is accomplished by loading the cells or through chambers of the core means 46, which extend transversely through the latter from sheathing face sheet 45 to the other sheathing face sheet 45, with granular material in a free-flowing condition. By reference to FIG. 17, it will be seen that the loading of the cells of the core means 46 may be r'eadily accomplished by first cementing a body of the core means 46 to the inner face 82 of one of the sheathing sheets 45 and then passing its sub-assembly along in the direction of the arrow 83 beneath a nozzle 84 to spill into the open cells a flow of granular material indicated at 85. Following the passage of the sub-assembly of sheathing sheet 45 and the superimposed body of core means 46 beneath the nozzle 84 to load the cells with granular material, the second sheathing sheet (45a) is then placed down upon the top of the core body with a suitable cement interposed to adhere the inner face (82a) of the second sheet to the core body, thereby completing the construction of the panel unit, such as that indicated at 32 or 132. It will be understood, of course, that side edges of the sheathing sheets 45 and 45a) preferably will, prior to cementing to the core body 46, be suitably shaped to provide the interlocking flanges, such as 47, 47 and 48, 48. Such loading of cells may constitute one step of a continuous procedure of manufacture disclosed and claimed in my copending patent application Serial No. 435,826, filed June 10, 1954.

The granular loading material to be employed in attaining sound suppression in accordance with one aspect of the present invention is to be of a character as to provide in the cells a loose free-flowing mass of relatively coarse particles having appreciable weight. It is known that transfer of sound through wall structures which have transversely-spaced sheathing face sheets intervened by various core means is attributable to an appreciable extent to the tendency for the sheathing sheets to act as coresponsive vibratory diaphragms. Sound waves striking one sheathing sheet vibrate it. The core means and/ or cells of air extending transversely therethrough cause transfer of such vibrations to the opposite sheathing sheet and the resultant drumming effect of the latter sets up sound waves, and this transfer constitutes the sound transmission factor. It has been found in accordance with the development of the sound suppression feature of the present invention that loading spaces intervening the sheathing face sheets, such as transverse core cells, with light-weight insulating material, such as mineral wool or small hollow bodies of the perlite type, does not effect the desired sound suppression. As contrasted with such results, partial to substantially full loading with granular relatively heavy material does provide appreciable sound suppression. It is not fully understood to what thi desirable result is attributable but it is believed that the presence of the masses of loose free-flowing granular material produces a damping effect with responsive vibration of the free particles absorbing energy which otherwise would be transmitted to produce transferred sound. Strangely enough the sound suppression does not bear a direct relation to the amount of loading. At certain frequencies, chiefly in the range of those of sounds of the type which cause the greatest trouble and annoyance in the occupancy of business building in cities, full loading shows no appreciable improvement over loading of a degree less than 50% of full loading. It is logical to assume that as the amount of granules is increased the greater will be the amount of energy absorbed since there is a greater number of granules responsively to vibrate for such absorption. However, as full loading is progressively approached there is decreasingly less space in which the granules can vibrate freely and there may be more loading of lower granules by greater masses of others resting thereon. Thus it is not improbable that the tendency for increases in the number of granules to increase the amount of energy absorbed is offset to a degree by the attendant limitation on the freedom of the granules to vibrate. This is important from the weight factor standpoint as heavily loaded planks or panels are more costly to package and ship and are more difficult to handle and install.

A variety of types of granular loading material will serve this sound suppression purpose. Coarse particulate 10,. minerals or granular inorganic materials of relatively heavy mass will serve, such as particulate quartz in the form of sand; crushed stone such as broken mica, shale, slate and mineral ores; small agglomerates of diatomaceous earth, clay, Portland cement and the like; beads of glass and other relatively heavy inorganics; metal particles such as filings; etc. By relatively heavy is meant specific gravities greater than that of water, preferably of the order of 2 and above, sand which is largely granular quartz having a specific gravity of 2.5 to 2.8, and sand may be a preferred granular loading material because of its cheapness and ready availability. The sizes of the granules or coarse particles may vary widely, for example, from about 0.01 to about 2.0 millimeters in diameter (sand particles vary in diameter from about 0.06 mm., in the form of silt, to about 2.0 mm., particles larger than the latter being considered small gravel). The effects of such loadings and the comparative results thereof with respect to the amounts employed are hereinafter set forth by way of example with respect to sand as the loading material due to the effectiveness of its use, its ready availability and the extremely low cost of its employment.

The following table indicate the advantageous sup pression of sound transfer attained by such loading of the' core cells'with granular material.

I. Transmission Loss of Partition Sections In Decibels at Certain Frequencies Well- Sand Loaded Slotted core Wellcore, #lSq. Load- Ilain Tilted ing Cycle Pekin Doug- Well- Slots 4 Frequency las 2 core 3 (No Sand Load- 1.1 1.4 2.54 7.5

Average 37. 1 36. 5 41. 5 38 39. 3 41. 1 45. 3 49. 3

In the compilation of the data set forth in Table I above partition sections of like dimensions were employed. Each section was 3 inches thick with the two sheathing face sheets of each formed of steel sheeting 0.025" thick. The Pekin 1 structure is standard in which the two sheathing sheets are intervened by core means in the form of a cellular structure having the cells extending transversely from sheet to sheet and defined by figure 8 or candy ribbon shaped strip of 60 lbs. kraft paper impregnated with 12-15% phenolic'resin. The Douglas structure is also standard in which the core means intervening the sheathing sheets is in the form of a honeycomb with the six-sided cells extending from sheet to sheet and defined by like phenolic resin-impregnated paper. The plain Wellcore 3 structure is that of Munters Patent 2,417,435, dated March 18, 1947, in which the core means is in the form of corrugated material with the cells also extending from sheet to sheet and defined by kraft paper which in the test samples was 30 lbs. kraft impregnated with about 15% of asphalt. The Wellcore structure 4 featuring tilted slots had slits extending laterally through the core means from side edge to side edge, each slit being about 0.8 wide and bisected by the mid-plane of the core means while making an acute angle of about 40 to a horizontal transverse plane across the plank, and with those tilted slots being spaced apart longitudinally of the plank about 0.75". The sand loaded planks were 3 slotted Wellcore planks desecribed above, in which the cells were loaded with various indicated amounts of sand expressed in terms of weight of loading in pounds per square foot of plank face area. 7.5 lbs/sq. ft. of sand loading constitutes practically complete filling of cells while 2.52 lbs/sq. ft. of sand closely approximates one-third filling of cells.

Although the range of frequencies of noticeable sounds most common to business building occupancy and in which the sounds causing most of the annoyance fall is from about 250 cycles per second to about 2000 cycles per second, the sound transmission losses which have been tabulated in Table 1 above were determined over a Wider range of from the lower frequencies of 128 cycles/ sec. to the higher frequencies of 3,000 cy-cles/ sec. to ascertain the sound suppressions in the fringe zones. It will be noted from this tabulated data that while at the unusually low frequency of 128 cycles/sec. the Pekin and Douglas planks seemed to provide more sound suppression than plain unloaded Wellcore and slotted unloaded Wellcore with the latter least effective, sand loading of the slotted Wellcore greatly improved its sound suppression characteristic. Further, it is there shown that at the unusually high frequency of 3,000 cycles/sec. both pain and slotted Wellcore planks gave bettersound suppressions than did the Pekin and Douglas planks and that fractional sand loading gave no appreciable improvement until complete filling was approached. In contrast therewith, in the range of usual frequencies of about 250 cycles/sec. to 2,000 cycles/sec. both plain and slotted unloaded Wellcore planks were as good and in many cases better suppressors than Pekin and Douglas planks with the slotted Wellcore plank beingless effective than the plain Wellcore plank. However, when the slotted We'lcore plank was sand loaded its sound suppression ability was materially improved with the one-third loading (2.52 lbsJ/sc}. ft.) being surprisingly close to the complete loading in the range of usual frequencies. Thus, from a practical standpoint one-third loading is the ideal ofthis feature of the present invention since full loading makes the planks and panel units too heavy for ready and economical shipping and easy handling. 'It has been found that appreciable sound suppression advantages'are attained within the practical loading range of about 1 lbQ/sq. ft. to about 4 lbs/sq. ft. (about A; to about A full loading), and that 'such loading wi l similarly improve various types of .panel units and planks having transversely-spaced sheathing face sheets intervened by core means characterized by transverse cells extending from sheet to sheet. The curve of FIG. 18 graphically illustrates such loading effects for 3" plain and uns'otted Wellcore panel units or planks having facing sheets of steel 0.025 thick, the practical range of sand loading andthe ideal of the latter, and the same curve for loaded slotted Wellcore panel units or planks would be of similar shape but a few decibels lower all along In order further to illustrate graphically the advantageous effect of sand loading in the suppression of transmitted sound there are plotted in FIG. 19 three curves representing sound transmission loss (suppression) in decibels (in the ordinates) with respect to sound frequencies -(in the abscissae) for three different loading conditions of 3" slotted Wellcore of the type described above. It will there be noted'that while sand loading appreciably improves sound transmission loss-in the usual range of frequencies of 250 cycles/sec. to 2,000 cycles/sec. approximately one-third of full loading shows-almost as much improvement of that characteristic in that range as does full loading. Also note that although full sand loading improves sound transmission losses'for frequencies below 250 cycles/sec. and above 2,000 cycles/sec. the advantages attainedby one-third offull loading drop off to none at ultra-low'frequencies-of about 100 cycles/ sec. and ultra-high frequencies of about 2,500 cycles/sec.

Normally the core means occupies from 3% to 12% of the total confined or intervening volume between the facing sheets. Thus the space available for the freefiowing granular mass is of the nature of 88% to 97% ofthe confined volumebetween the facing sheets. The desiredloading will therefore result in the filling of from about 15% to 60% ofthe volume-when using a loading material with a density similar to that of sand. Per- 12 haps a loading material with greater density should occupy a proportionately lower percentage of the con fined volume and a loading material with lower density should occupy a proportionately higher percentage of the confined volume.

It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

Having described my invention, what I claim as new and desire to secure by Letters Patent is:

l. A structural building panel unit comprising a pair of transversely-spaced sheathing face sheets, core means intervening said sheets and having a plurality of transversely-extending cells, and masses of free-flowinggranular material loaded in said ce'ls in quantities greater than about one-eighth of those'sufficient completely to fill said cells.

2. A structural building panel unit comprising a pair of transversely-spaced sheathing face sheets, core means intervening said sheets and having a plurality of transversely-extending cells, and masses of free-flowing granular material loaded in said cells in quantities from about one-eighth to about one-half of those'sufiicient completely to fill said cells.

3. A structural building panel unit comprising a pair of transverse'y-spaced sheathing face sheets, core means intervening said sheets and having a plurality of transver'sely-extending cells, and masses of free-flowing granular material loaded in said cells in quantities of about one-third of those sufficient completely to fill said cels.

4. A structural building panel unit comprising a pair of transversely-spaced sheathing face sheets, core means intervening said sheets and having a plurality of cells extending transversely from face sheet to face sheet, and masses of free-flowing granular material of a specific gravity of the order of about 2.0 and greater loaded in said cells in quantities from about one-eighth to about one-half of those sufficient completely to fill said cells.

5. A structural building panel unit comprising a pair of transversely-spaced sheathing face sheets, core means intervening said sheets and having a'plurality of cells extending transversely from face sheet to face sheet, and masses of free-flowing granular material of a specific gravity of the order of about 2.0 and greater loaded in said cells in quantities of about one-third of those sufficient completely to fill said cells.

6. A structural building panel unit comprising a pair of transverse y-spaced sheathing face sheets, core means intervening said sheets and having a plurality of cells extending from face sheet to face sheet, and free-flowing masses of sand loaded in'said cells in quantities from about one-eighth to about one-half of that-sufficient completely to fill said cells.

7. Astructural building panel unit comprising a pair of transversely-spaced sheathing facesheets, core means intervening said sheets and having a plurality of cells extending from face sheet to face sheet, and free-flowing masses of sand loaded in said cells in quantities of about one-third of those'sufficient completely to fill'said cells.

8. A structural building'panel unit comprising a pair of transversely-spaced sheathing face sheets, a core body intervening and cemented to said sheets comprising impregnated paper defining a plurality of relatively thinwalled juxtaposed cells extending transversely from'sheet tosheet, and free-flowing masses of sand loaded in said 13 cells in quantities greater than about one-eighth of those which are sufllcient completely to fill said cells.

9. A structural building panel unit comprising a pair of transversely-spaced sheathing face sheets, a core body intervening and cemented to said sheets comprising impregnated paper defining a plurality of relatively thinwalled juxtaposed cells extending transversely from sheet to sheet, and free-flowing masses of sand loaded in said cells in quantities of the order of about one-third of those sufficient completely to fill said cells.

References Cited in the file of this patent UNITED STATES PATENTS Sabine et a1. Nov. 23,

Ries Oct. 24,

Mayer Feb. 2,

Lyford Sept. 20,

Denning May 8,

FOREIGN PATENTS France Jan. 5,

Great Britain Oct. 8, 

